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Starch production is an isolation of starch from plant sources. It takes place in starch plants. Starch industry is a part of food processing which is using starch as a starting material for production of starch derivatives, hydrolysates, dextrins.
At first, the raw material for the preparation of the starch was wheat. Currently main starch sources are:
The production of potato starch comprises the steps such as delivery and unloading potatoes, cleaning, rasping of tubers, potato juice separation, starch extraction, starch milk refination, dewatering of refined starch milk and starch drying.[ citation needed ]
The potato starch production supply chain varies significantly by region. For example, potato starch in Europe is produced from potatoes grown specifically for this purpose. However, in the US, potatoes are not grown for starch production and manufacturers must source raw material from food processor waste streams. The characteristics of these waste streams can vary significantly and require further processing by the US potato starch manufacturer to ensure the end-product functionality and specifications are acceptable.[ citation needed ]
Potatoes are delivered to the starch plants via road or rail transport. Unloading of potatoes could be done in two ways:
Coarsely cleaning of potatoes takes place during the transport of potatoes to the scrubber by channel. In addition, before the scrubber, straw and stones separators are installed. The main cleaning is conducted in scrubber (different kinds of high specialized machines are used). The remaining stones, sludge and light wastes are removed at this step. Water used for washing is then purified and recycled back into the process.
Most often the rasping of potato tubers is carried out with a rotary grater. The purpose of this stage is disruption of cell walls, which therefore release the starch. In practice, potato cells are not entirely destroyed and part of the starch remains in the mash. Potato pulp rapidly turns dark, because tyrosine presented in the potato is oxidised by polyphenol oxidase, which is located in the cellular juice. Therefore, cellular juice must be separated as soon as possible.
This allows the recovery full-value protein from juice and reduces the onerousness of water juice as a sludge.
After separation of potato juice the pulp is directed to the washing starch station, to isolate the starch. Most used are stream-oriented washers. In these machines pulp diluted with water is washed with a strong stream of water to flush out the milk starch. The mash smuggling with water is a waste product – dewatered potato pulp. Starch milk is contaminated by small fiber particles (potato tissue fragments) and the remaining components of the potato juice – that is why it is called raw starch milk.
Raw starch milk is purified in the refining process. This involves the removal of small fibers from the starch milk and then the removal of juice water and starch milk condensation. For this purpose, the screens and hydrocyclones are commonly used. Hydrocyclones due to the low output (approximately 0.3 cubic meter per hour) are connected in parallel and works as multihydrocyclones. For the starch milk desanding bihydrocyclones are used. In order to prevent enzymatic darkening of potato juice the chemical refining of starch is carried out using sulfurous acid. Refined starch milk has a density of about 22° Be, which is about 38% of starch.
It is a suspension of starch in water, which needs dewatering up to 20% of moisture. This is equivalent to the moisture content of commercial starch when stored. High temperatures cannot be used in this process because of the danger of starch gelatinization which destroys granular structure. It may result in significant changes of the functional starch properties. Therefore, removal of excess water from milk shall be done only under conditions that prevent the gelatinization of starch.
Dewatering of refined starch milk is carried out in two stages. In the first stage the excess water is removed by means of a rotary vacuum filter. Secondly moist starch is dried, without starch pasting. For this purpose a pneumatic dryer is used. In this device moist starch (with water content 36 – 40%) is floating in strong and hot (160 °C) air flow and then dried during 2 – 3 seconds. Then, the starch is separated from hot air in cyclones. Due to short time of high temperature drying and intensive water evaporation from the starch granules, its surface is heated only to 40 °C.
Dried starch contains about 21% of water. During the pneumatic transport starch loses additional 1% of water.
Received starch is storing separately in silos, in jute bags (100 kg) or paper bags (50 kg). There are three kinds of starch: superior extra, superior and prima. Different sorts of starch depend on degree of purity and whiteness. The differences between them are in an acidity and content of mineral substances.
Table 1. Potato starch production characteristic.
Processing | 2.000 t per 24 hours |
---|---|
Ratio of starch extraction | 87% |
Water expenditure: - washing - technological | 6.5m3/t 2.5m3/t 4.0m3/t |
Water steam expenditure | 400 – 500 kg/t starch |
SO 2 expenditure | 0.8 kg/t potatoes |
Yield: per ton of potatoes | (16,8%) 175 kg starch |
Loss: - potatoes losses (transport and washing) - pulp starch losses -juicy water starch losses | about 10% 0.5% 8 – 9% 1.0% |
The water which is used in starch production (dirty water) for transportation and cleaning does not have to be totally clean. That is why clarifier usage enables application of closed cycle which noticeably reduces amount of cleaning water that is needed. On the other hand, requirements for quality of technological water are the same as for drinking water (microbiological and chemical contamination). In addition, this type of water should contain low amounts of metals such as: Ca, Mg, Fe, Mn; which has bad influence on starch properties.
- Potato juice is a liquid waste product separated from the potatoes pulp after the rasping, using centrifuges or decanters. It contains about 5% of dry substance, including about 2% valuable protein of the potato of high nutritional value, minerals, vitamins and other. Modern starch plants separate the juice from the mash. [1]
- Potato protein can be extracted from the juice by coagulation with heat at low pH. About 600 kg of coagulated protein from each 1000 kg of potato protein can be recovered this way. The coagulated protein product contains about 80% protein (with the digestibility of about 90%), 2.5% minerals, 1.5% fat, 6% nitrogen-free substances and 10% water. Because of the full range of the exogenic amino acids the formulation is a valuable protein feed. The remaining potato juice is used as fertilizer.
- Potato pulp is a side product of washing the starch from the mash. It contains all non-starchy substances insoluble in water (fragments of wall of cells) fibres and bounded starch which cannot be mechanically separated from the blended parties of potato. The dry substance of the pulp contains 30% of starch, which makes it a good source for animal feed for cows. The pulp contains a lot of water, dry solids about 16%, which is inconvenient in transportation and storage. That is why it is really often dried and dehydrated.
- Juicy water is a liquid side product obtained after refining of starch milk. It is ten times diluted potato juice. As it is a sludge and it cannot be discharged to open water. It must be treated as waste water or is used as fertilizer. [2]
The usage of raw starch is relatively small. Starch is mainly used as material both in the manufacture of food and non-food products. In food processing a lot of starch is converted to starch hydrolysates. Also it is used to receive puddings, jellies, desserts, caramel and other food products. In addition, starch is processed to modified starch in order to change material properties. The modified starches have a wide range of applications in many industries. Applications of starch in non-food sectors include: production of dextrin and adhesives, drilling fluids, biodegradable plastics, gypsum binders and many other. In addition modified starches are used as emulsion stabilizers. Other important fields of starch application are textile sizing agents, excipient in tablets for pharmaceuticals.
Malt is germinated cereal grain that has been dried in a process known as "malting". The grain is made to germinate by soaking in water and is then halted from germinating further by drying with hot air.
Pasta is a type of food typically made from an unleavened dough of wheat flour mixed with water or eggs, and formed into sheets or other shapes, then cooked by boiling or baking. Rice flour, or legumes such as beans or lentils, are sometimes used in place of wheat flour to yield a different taste and texture, or as a gluten-free alternative. Pasta is a staple food of Italian cuisine.
Rennet is a complex set of enzymes produced in the stomachs of ruminant mammals. Chymosin, its key component, is a protease enzyme that curdles the casein in milk. In addition to chymosin, rennet contains other enzymes, such as pepsin and a lipase.
Orange juice is a liquid extract of the orange tree fruit, produced by squeezing or reaming oranges. It comes in several different varieties, including blood orange, navel oranges, valencia orange, clementine, and tangerine. As well as variations in oranges used, some varieties include differing amounts of juice vesicles, known as "pulp" in American English, and "(juicy) bits" in British English. These vesicles contain the juice of the orange and can be left in or removed during the manufacturing process. How juicy these vesicles are depend upon many factors, such as species, variety, and season. In American English, the beverage name is often abbreviated as "OJ".
Flour is a powder made by grinding raw grains, roots, beans, nuts, or seeds. Flours are used to make many different foods. Cereal flour, particularly wheat flour, is the main ingredient of bread, which is a staple food for many cultures. Corn flour has been important in Mesoamerican cuisine since ancient times and remains a staple in the Americas. Rye flour is a constituent of bread in central and northern Europe.
Tapioca is a starch extracted from the storage roots of the cassava plant, a species native to the North and Northeast regions of Brazil, but whose use is now spread throughout South America. It is a perennial shrub adapted to the hot conditions of tropical lowlands. Cassava copes better with poor soils than many other food plants.
The cashew tree is a tropical evergreen tree that produces the cashew seed and the cashew apple accessory fruit. The tree can grow as high as 14 m (46 ft), but the dwarf cultivars, growing up to 6 m (20 ft), prove more profitable, with earlier maturity and greater yields. The cashew seed is commonly considered a snack nut eaten on its own, used in recipes, or processed into cashew cheese or cashew butter. Like the tree, the nut is often simply called cashew. Cashew allergies are triggered by the proteins found in tree nuts, and cooking often does not remove or change these proteins.
Curd is obtained by coagulating milk in a sequential process called curdling. It can be a final dairy product or the first stage in cheesemaking. The coagulation can be caused by adding rennet or any edible acidic substance such as lemon juice or vinegar, and then allowing it to coagulate. The increased acidity causes the milk proteins (casein) to tangle into solid masses, or curds. Milk that has been left to sour will also naturally produce curds, and sour milk cheeses are produced this way. Producing cheese curds is one of the first steps in cheesemaking; the curds are pressed and drained to varying amounts for different styles of cheese and different secondary agents are introduced before the desired aging finishes the cheese. The remaining liquid, which contains only whey proteins, is the whey. In cow's milk, 90 percent of the proteins are caseins.
Industrial wastewater treatment describes the processes used for treating wastewater that is produced by industries as an undesirable by-product. After treatment, the treated industrial wastewater may be reused or released to a sanitary sewer or to a surface water in the environment. Some industrial facilities generate wastewater that can be treated in sewage treatment plants. Most industrial processes, such as petroleum refineries, chemical and petrochemical plants have their own specialized facilities to treat their wastewaters so that the pollutant concentrations in the treated wastewater comply with the regulations regarding disposal of wastewaters into sewers or into rivers, lakes or oceans. This applies to industries that generate wastewater with high concentrations of organic matter, toxic pollutants or nutrients such as ammonia. Some industries install a pre-treatment system to remove some pollutants, and then discharge the partially treated wastewater to the municipal sewer system.
Instant mashed potatoes are potatoes that have been through an industrial process of cooking, mashing and dehydrating to yield a packaged convenience food that can be reconstituted by adding hot water or milk, producing an approximation of mashed potatoes. They are available in many different flavors.
Sewage sludge treatment describes the processes used to manage and dispose of sewage sludge produced during sewage treatment. Sludge treatment is focused on reducing sludge weight and volume to reduce transportation and disposal costs, and on reducing potential health risks of disposal options. Water removal is the primary means of weight and volume reduction, while pathogen destruction is frequently accomplished through heating during thermophilic digestion, composting, or incineration. The choice of a sludge treatment method depends on the volume of sludge generated, and comparison of treatment costs required for available disposal options. Air-drying and composting may be attractive to rural communities, while limited land availability may make aerobic digestion and mechanical dewatering preferable for cities, and economies of scale may encourage energy recovery alternatives in metropolitan areas.
Sake kasu (酒粕) or sake lee is a cooking ingredient that is white in color with a paste-like texture. The taste of sake kasu is fruity and has a similar taste to Japanese sake. Sake kasu is the lees left over from sake production. It is a by-product of Japanese sake production that contains 8% of alcohol, high nutritious values and provides health benefits. Sake Kasu can be used as a marinade base in different Japanese dishes such as fish, vegetables, and meat, enhancing the umami flavor of the dish. Sake kasu can also be found in cosmetics and skincare products. Sake kasu is considered as a part of the Japanese “no waste” culture since the waste of the sake production is used in various ways. Mirin, a type of sweet Japanese sake can also produce kasu called mirin kasu. Similar to sake kasu, mirin kasu can also be used as a healthy food ingredient.
Tofu, also known as bean curd, is a food prepared by coagulating soy milk and then pressing the resulting curds into solid white blocks of varying softness; it can be silken, soft, firm, extra firm or super firm. Beyond these broad textural categories, there are many varieties of tofu. It has a subtle flavor, so it can be used in savory and sweet dishes. It is often seasoned or marinated to suit the dish and its flavors, and due to its spongy texture it absorbs flavors well.
A great variety of cassava-based dishes are consumed in the regions where cassava is cultivated, and they include many national or ethnic specialities.
The belt filter is an industrial machine, used for solid/liquid separation processes, particularly the dewatering of sludges in the chemical industry, mining and water treatment. Belt filter presses are also used in the production of apple juice, cider and winemaking. The process of filtration is primarily obtained by passing a pair of filtering cloths and belts through a system of rollers. The system takes a sludge or slurry as a feed, and separates it into a filtrate and a solid cake.
A dewatering screw press is a screw press that separates liquids from solids. A screw press can be used in place of a belt press, centrifuge, or filter paper. It is a simple, slow moving device that accomplishes dewatering by continuous gravitational drainage. Screw presses are often used for materials that are difficult to press, for example those that tend to pack together. The screw press squeezes the material against a screen or filter and the liquid is collected through the screen for collection and use.
A solid bowl centrifuge is a type of centrifuge that uses the principle of sedimentation. A centrifuge is used to separate a mixture that consists of two substances with different densities by using the centrifugal force resulting from continuous rotation. It is normally used to separate solid-liquid, liquid-liquid, and solid-solid mixtures. Solid bowl centrifuges are widely used in various industrial applications, such as wastewater treatment, coal manufacturing, and polymer manufacturing. One advantage of solid bowl centrifuges for industrial uses is the simplicity of installation compared to other types of centrifuge. There are three design types of solid bowl centrifuge, which are conical, cylindrical, and conical-cylindrical.
Reuse of human excreta is the safe, beneficial use of treated human excreta after applying suitable treatment steps and risk management approaches that are customized for the intended reuse application. Beneficial uses of the treated excreta may focus on using the plant-available nutrients that are contained in the treated excreta. They may also make use of the organic matter and energy contained in the excreta. To a lesser extent, reuse of the excreta's water content might also take place, although this is better known as water reclamation from municipal wastewater. The intended reuse applications for the nutrient content may include: soil conditioner or fertilizer in agriculture or horticultural activities. Other reuse applications, which focus more on the organic matter content of the excreta, include use as a fuel source or as an energy source in the form of biogas.
Corn wet-milling is a process of breaking corn kernels into their component parts: corn oil, protein, corn starch, and fiber. It uses water and a series of steps to separate the parts to be used for various products.
Bellmer GmbH is a company founded in 1842 in Niefern, Germany by Carl Bellmer. It is still family-owned with over 600 employees globally. Bellmer operates 16 sites around the world but the products are manufactured in Germany and Finland.
Mieczysław Pałasiński, 2005. Technology of Carbohydrate Processing (in Polish). Polish Society of Food Technologists, Małopolska Branch, Kraków, p. 63 - 76.